Punchbox 3D model preview
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About this 3D model

Punchbox, the puzzle in a puzzle and a secret box I finally managed to get a decent print for each part using a wood fill filament, but the printer still needs a lot of work to be more reliable. I've been plagued with problems beyond imagination (y-axis leveling, motors overheating, thermal runaways, bed adhesion, z-probe failures, destroyed nozzles, the list goes on..)I initially wanted this box to be smaller, 6cm x 6cm x 6cm, but the ordered neodimium magnet balls of 3mm haven't arrived so I had to redesign with the 5mm version. Spoiler alert: viewing the 3D model files or reading this text thouroughly will make solving this puzzle a lot easier, so if you're into puzzling, don't look into the stl files as this will spoil any fun trying to solving this.I'm in no way a professional designer, photographer or content provider. 3D printing turned into a hobby because of how these machines work. More information below in the background section.Update: the hotend cooling fan died during my last attempt (I'm still trying) resulting in a completely blocked heatbrake and nozzle. The 3mm magnet balls have finally arrived (see shared Google album) and they look amazing! Currently designing the smaller version.After extensive testing of the punchbox, I still feel there's room for improvment in many areas. The most important area is the overall sturdyness of the box once put together: there's simply too much play for it to function properly when being punched, so the pegs don't always move as intented since the punch itself displaces some of the sides just little enough for the pegs to not slide out. I'm currenlty investigating how I can redesign the parts so they lock better, without sacrifycing the printability or the supportless print option. Introduction I was heavily inspired by the amazing puzzles I've seen being reviewed on YouTube (thanks Mr.Puzzle and Chris Ramsay) and especially the ones where hidden pegs are holding the puzzle together intrigued me. I'm also a huge fan of the neodimium magnet balls so I started my design using these tiny but powerfull magnets as locking mechanism. Since I love the idea to punch or slap the puzzle box, I came up with the idea to design a box that requires at least five punches to be opened. These punches have to be executed in a particular way for the box to open, turning it into some kind of cryptex if you would label the sides of the cube. Design Process I started with a pencil draft trying to figure out where to put the sliding pegs in each side of the cube (since I wanted to have a lot of punches). I quickly figured that the best place to put them is inside the edges of the cube, leaving as much inner space available as possible. I though of designing this in one piece (except for the lid), trying to print in place like Devin showed with his printer music video's. This however turned out to be quite difficult, so I quickly turned to redesigning the puzzle in 6 separate parts that are much easier to print. I thought it would be amazing if the six sides could be identical, but the cover had to be different anyways so I let go of this constraint early in the process. Then I wanted to not be forced to use glue, so I added some interlocking parts to the individual pieces without blocking the sides that hold the pegs. I love the Japanese woodworking skills so I thought to go with the famous dovetail joints where possible and make the lid slide off diagonally. The pieces are similar but not identical, and assembly turned out to be a puzzle on it's own (albeit not very difficult) with the added bonus that it clearly demonstrates how the mechanism works once the box is opened. All the pegs are visible and removable once taken apart, making it a nice fiddling toy to re-assemble. Design Experience I discovered some unexpected drawbacks in every step of the process, from Fusion 360 creating cloned copies instead of individual ones to bed adhesion issues when trying to print. I added more photos in a public Google album since I feel these don't really belong here. I will still try to print the final cube in greenwood woodfill filament and use a bronze fill for the pegs since the extra weight will add some momentum to the locking mechanism. I have both filaments at hand but besides the pegs (or sliders) all my attempts to print have been fruitless due to technical issues. Currently one side takes about 2 hours to finish. I added holes in the sides to be able to push a magnet ball inside, leaving enough clearance for it to rotate freely once secured (just like with the pegs) so they can orient themselfs to have the best magnetic attraction. The latest version (I deleted the previous ones) is the final one: I replaced the invisible dovetail joint with a version that doesn't require supports (allthough it helps if you do as explained in the printing tips). I also added the final holes to put the magnets in each side so the sliders snap nicely from one position to the other, making sure no